Recent Trends Flot Fine Particles

Journal of Mining World Express Volume 3, 2014 www.mwe‐journal.
org
doi: 10.14355/mwe.2014.03.009
Recent Trends in Flotation of Fine Particles
Fatma H. Abd El‐Rahiem
Central Metallurgical Research and Development Institute (CMRDI)
P.O. Box: 87, Helwan, Cairo, Egypt

Abstract due to the limitation of the conventional methods of
Fine particles are generated at the mines due to the beneficiation to recover the valuable minerals in such
mechanization and automation in the mining processes. size with a reasonable efficiency and recovery.
Also, the occurrence of valuable minerals in a finely
At the same time, the small mass and momentum of
disseminated form necessitates fine grinding for liberation
fine gangue particles make them either entrained in
and subsequent physical separation. Because of the
extremely complicated physico‐chemico‐mechanical the liquid of the froth or mechanically entrapped with
conditions existing in the flotation process, the problems particles being floated.
associated with the presence of fine particles are most For these reasons, a number of new approaches to
pronounced in flotation. New trends to flotation of fine
recover the fine and ultrafine particles have been
particles are carrier flotation, column flotation and bio‐
proposed. Developing any new processing method to
flotation.
treat such fines has to meet, at the same, the present
The carrier flotation technique is applied for upgrading of day energy, environmental and economical
Egyptian kaolin and graphite. The carrier flotation technique
constraints.
has the advantage of reducing the long conditioning time
needed for the pulp with the reagents in the conventional These major developments in the flotation of fine
technique. But, the main draw backs of carrier flotation particles can be classified into two categories:
process in mineral beneficiation operations, are high reagent
consumption and the necessity for subsequent separations a–processes which are based primarily on increasing
of valuables from the carrier particles (when the valuable the probability of collision between air bubbles and
minerals are being recovered in the froth) . mineral particles and
There is a great potential to recover of fine particles from b‐processes which are based on more favorable
their gangue using the recent technology such as column change in the energetic of bubble – particle contact.
flotation or Air Sparged Hydrocyclone (ASH), after its
modification to be suitable for flotation of very fine particles The probability of collision between air bubbles and
to beneficiate many ores such as kaolin, talc, graphite, mineral particles increases when latter is presented
phosphate and hematite. as agglomerates (floc‐flotation) or is attached to larger
(hydrophobic) particles which act as carrier particles
Bacteria and enzyme were used in the bio‐flotation process
to beneficiate the dolomitic phosphate to decrease MgO%. (carrier flotation). Such technique was suggested for
kaolin ores. Meanwhile, Production of fine bubbles of
Keywords
larger residence time in the column flotation improves
Fine Particles; Column Flotation; Carrier Flotation; Bio‐Flotation the floatability of such fine and ultrafine particles. At
the same time, applying the wash water in the column
Introduction helps in removing the entrained fine gangue particles
leading to a product of high grade.
The Inevitable Production of Fines during Ore Mining
and Beneficiation
Flotation Processes
In recent years remarkable amounts of fine particles
Flotation process is the most important process in ore
are generated at the mines due to the mechanization
beneficiation in the world. It is used in beneficiation of
and automation in the mining processes (Abd El‐
many minerals, in Table 1, for example, amount of
Rahiem, 1997). Also, the occurrence of valuable
ores are treated by flotation in USA, and in Table 2,
minerals in a finely disseminated form necessitates
recent consumption (in tones) by flotation plants in
fine grinding for liberation and subsequent physical
1985 (PERC report, 2000).
separation. The fines represent an immense challenge
63
www.mwe‐journal.org Journal of Mining World Express Volume 3, 2014
TABLE 1 AMOUNT OF ORES TREATED BY FLOTATION IN THE USA (PERC this view – if you sample almost any flotation plant
REPORT, 2000)
you will produce a similar curve. The numbers speak
Amount for themselves – fine particles float poorly in most
Ore
plants. Operators carefully avoid “over grinding” and
Type of ores Concentrated Reagents “sliming” of feed (Pease, et al., 2004).
treated,
products, consumed,
million
million tones million kg
tones
Coal 25.16 17.170 6.000
Copper 176.56 5.300 209.420
Feldspar‐ 1.900 1.300 3.200
Mica‐ Quart
Glass Sand 2.500 2.900 3.500
Iron 22.00 17.600 47.600
Lead‐ Zinc 3.300 0.700 1.400
Phosphate 109.500 24.600 226.100
Potash 10.100 1.500 3.200
TABLE 2 RECENT CONSUMPTION (IN TONES) BY U.S. FLOTATION PLANTS
IN 1985 (PERC REPORT, 2000)
Sulfide Nonmetallic
Types of reagent Coal
ores ores
Modifiers 281,893 80,408
353,000 FIG.1 TYPICAL RECOVERY VS SIZE CURVE (PEASE, ET AL.,
Collectors 10,108 154,043
2,682 2004)
Activators 8,090 288,000

Depresants 13,348 2,130

Because of the extremely complicated physico‐
Frothers 4,360 522,000
1,700 chemico‐mechanical conditions existing in the
Flocculalions 540,000 516,000
Dispersants 161,000 223,000
1,275 flotation process, the problems associated with the
presence of fine particles are most pronounced in
Total 318,800 238,130 6,010
flotation. There is a general agreement that flotation
decreases with a decrease in particle size in the fine
Flotation is a method of concentrating finely divided particle range.
mineral particles in water on the basis of variations in
Two characteristics begin to dominate as the particle
their ability to keep themselves on a phase interface.
size is reduced: the specific surface becomes large and
The particles to be separated float out, together with
the mass of the particle becomes very small. Fig.2
the phase to which they have attached themselves.
illustrates the relationship between the physical and
The process is subdivided by El‐Shall (El‐Shall, 1994)
chemical properties of fine particles and their behavior
into froth, film and oil flotation. Recent flotation
in flotation (Chander, 1978).
processes such as carrier flotation and column
flotation have also been adopted. Froth flotation is the Because of the small mass and momentum of fine
usual method of flotation where the selected mineral particles, they may be carried into the froth after
particles are separated in the form of the froth. getting either entrained in the liquid or mechanically
entrapped with particles being floated. Some authors
Froth Flotation Processes (Pease, et al., 2004) have shown that the fine particles
are carried into the froth as mechanical in layers of
1) Flotation Problems of Fine Particles
water are attached to air bubbles. When such particles
The flotation process may be conceptualized in terms are of gangue minerals, the effect is a reduction in the
of a large number of subprocesses, most of which are grade of the concentrate. The large specific surface of
still rather poorly understood. A complete review of fine particles increases the adsorption capacity of
all the sub‐processes would be too lengthy. Several reagents when considered on a mass basis. Thus, a
review articles have appeared in recent years which significant proportion of the reagent is consumed by
look at some of the important aspects of the sub ‐ small particles. When present in the limited amount,
processes in flotation (Chander, 1978). sufficient reagent may not be available for the
flotation of larger particles, with a resultant decrease
The conventional view of the flotation size‐recovery in recovery (Chander, 1978).
curve is shown in Fig. 1. There is a good reason for
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Journal of Mining World Express Volume 3, 2014 www.mwe‐journal.org
Problems of Fine Particles flotation.
Fine Particles Carrier Flotation of Fine Particles

Carrier flotation can be achieved via the enhanced
Small mass High specific Surface aggregation between fine (carried) and coarse (carrier)
particles under intense agitation and follow by froth
Low momentum High adsorption
High reagent flotation. The common and critical requirements for
consumption
carrier flotation are:
Entrainment High charge Non specific adsorption 1. presence of coarse particles

2. use of higher energy agitation , and
High surface energy Rapid oxidation 3. hydrophobicity of the carrier (coarse) and
carried (fine) particles (Xu and Wells, 2004).
High surface dissolution The process of ultraflotation is schematically
illustrated in Fig.4. Fine particles to be floated from
FIG.2 SCHEMATIC DIAGRAM SHOWING THE RELATIONSHIP slime coatings on the auxiliary or carrier material, and
BETWEEN THE PHYSICAL AND CHEMICAL PROPERTIES OF the coated particles are then floated (Waksmundzki et
FINE PARTICLES AND THEIR BEHAVIOR IN FLOTATION al., 1971). The first commercial use of this process was
(CHANDER, 1978)
in the purification of kaolin at Minerals and Chemicals
The process of slime coatings refers to the attachment Phillipp’s plant at Mc Intyre, Georgia (Hummadi, et
of fine particles to larger particles, Fig.3 such slime al., 1994). The process was originally developed to
coatings can be detrimental to flotation in several upgrade kaolin clay. Titaniferous impurities were
ways. If the fine particles are the valuable mineral and removed with 60 micron limestone particles as the
the coarse particles are the gangue minerals, the grade carrier mineral.
of the concentrate becomes poor. When the fine
Jenkins et al. have reviewed the use of carrier flotation
particles consist of gangue minerals that coat the
technique for removal of colloidal impurities as
coarse particles of the valuable mineral, these particles
bacteria, silica, clays, metal oxides and humic acid
prevent the attachment of air bubbles and the
from natural waste waters. The general conditions
recovery of valuable mineral may then decreases necessary for successful removal of these colloidal
significantly (Chander, 1978). particles include coagulation or attachment of the
particles onto the surface of the large size particles
(carrier mineral), finding a suitable collector, frother,
and floating the agglomerates in a flotation cell. In this
application, the process objective is complete removal
of all the colloidal particles, rather than selective
separation as desired in mineral beneficiation. In the
latter case, conditions are sought where only mineral
particles are attached to the carrier mineral floated
(Chander, 1978).

FIG. 3 RECOVERIES AS A FUNCTION OF TOTAL VOLUME OF
PARTICLES<10 (CHANDER, 1978)
The possibility to improve the floatability of fine

particles is to increase the probability of collision FIG.4 SCHEMATIC REPRESENTATION OF THE
between these fines and the air bubbles (Xu and Wells, UTRAFLOTATION OR CARRIER FLOTATION PROCESS
2004). Such attempt has been made through column (WAKSMUNDZKI ET AL., 1971)
65
It is not always necessary to externally add particles as The principle operating features of column flotation

coarser particles originally presented may act as the are as follows:
carrier. Accidental ultraflotation in such a case is
a) No moving parts. Solids are kept in a suspension
detrimental to the grade of the concentrate if the
not by an agitating action of a propeller but by the
coarse particles comprised are of gangue minerals.
rising air bubbles.
When coarse particles are inherently presented which
may act as carrier particles the addition of carrier b) Wash water. Spray pipes are installed below the
mineral may or may not improve the process. froth surface and they deliver the required volume of
The main draw backs of this process in mineral water.
beneficiation operations are high reagent The purpose of this water is of twofold:
consumption and the necessity for subsequent
I) it washes the raising froth in the lower flotation
separations of valuables from the carrier particles
(when the valuable minerals are being recovered in section thereby displacing entrained hydrophilic
the froth) (Wang et al. 1988). (gangue) particles that have been reported to the froth
phase. As a result, the concentrate produced is of
Flotation of Fine Particles higher purity than in the conventional flotation. The
column is characterized by a very high up grading.
The technique of column flotation has been developed
to utilize the principle of the counter current flow to ii) it keeps in balance the flow of material through the
improve separations in the flotation of fine particles. column .
The column flotation offers a solution for the c) Flow balance. For the correct operating conditions
removal of entrained fine gangue particles by the volume of the underflow (tail) is larger than that of
using a counter ‐ current flow of wash water the feed. The wash water makes up this difference.
(Fuerstenau, D. W., 1979). This difference is called bias.
The column differs dramatically from conventional In the column flotation, there exist two distinct
mechanical flotation machines, both in design and regions: the flotation region, which extends from the
operation philosophy, which has been a principal point of the feed inlet to the point of aeration and the
reason for its slow acceptance by the mineral industry. cleaning region, which covers the region between the
The concept was developed in the 1960’s in Canada feed addition and the froth overflow.
and since then the plant and laboratory column have
been marketed commercially by the column Flotation A typical flotation column is shown in Fig.6. This
Company of Canada Ltd (Dobby, et al., 1985). figure suggests four distinct zones. These zones have
been defined as:
Principles of Column Flotation
Beneficiation Zone 1: The froth phase cleaning zone.
The flotation column is a long tube, either of a square This zone extends from the top of the column to
or circular cross section with dimensions of 300 mm to slightly above the pulp‐froth interface.
3 m (side length or diameter) and a length ‐to‐
Beneficiation Zone 2: The pulp‐froth interfacial zone.
diameter ratio of 10 to 100 (Al‐Maghrabi, 2004)
The boundaries of this zone are at slightly above the
Laboratory columns are 20‐60 mm in diameter and 3‐
pulp‐froth interface and slightly below the pulp‐froth
10 m in height. A reagentized pulp enters the column
interface. The primary upgrading is a function of this
at about 1/4th to 1/3rd of the distance from the top of
zone. Hydrophilic minerals are rapidly rejected in this
the column. Inside the column it meets a downward
zone as a result of their preference for the liquid
flowing stream of water and an upward flowing mass
phase.
of air bubbles (Al‐Maghrabi, 2004). Flotation takes
place in this counter current system. The hydrophobic Beneficiation zone 3: The pulp phase cleaning zone.
particles are collected by the air bubbles and carried This zone begins slightly below the pulp‐froth
upward to the top of the column, producing a mineral interface and extends down to the feed slurry injection
‐ rich froth and a tailing of the hydrophilic particles, ‐ inlet.
which leave with the slurry at the bottom of the Beneficiation Zone 4: The collection zone. This zone
column Fig. 5. includes the length of the column from the feed slurry
66
injection part to the air sparger at the base of the sparger.
column. In this zone, an initial contact between the
settling feed slurry and rising bubbles occurs.
These zones are characterized according to the
normalized percent mineral upgrading per height of
each zone. The boundaries of zones 1,2,3 and 4 are set
by physical limits, however, those of the pulp‐froth
interfacial zone are arbitrary .
Industrial columns have a height of 9‐14 m, and a
diameter of not more than 2 m, without baffling.
Usually they are operated with sufficient over head
wash water to provide a net down ward flow of water,
a condition known as a positive bias (Abdel‐Khalek
1989).
Positive bias has been norm in column operation
because the wash water stabilizes the froth layer in a FIG.5 SCHEMATIC REPRESENTATION OF A FLOTATION
column. The greater flow of water down the column, COLUMN
the greater the selectivity and the chicaner froth layer. For a 10 m Pt is approximately twice Pc, so that Jg ~
The depth froth in stable is somewhat over a meter. A 0.69 cm/second. The effect of gas velocity on recovery
negative bias will eliminate the froth altogether, very and grade is dominated by bubble size, which is
deleterious for a process where the concentrate is a affected by both the absolute amount of gas fed to the
desired product, but in case of coal cleaning, when the column as well as the pore size of the sparger. In
reagent selection results in the lower volume produce practice, bubble sizes can range from 0.2 to 0.3 mm;
(ash) going to the tails (Abdel‐Khalek, 1989). industrially, a target range for normal pulp mesh sizes
is 0.4 – 0.8 mm. Because bubble size is a function of the
A major factor that must be kept in mind in the design porosity of the sparger, the type and quantity of
of dressing experiments with columns is that the rate frother present, and the gas rate, it is not possible to
controlling flotation mechanism is always bubble generalize on the effect of the gas rate or recovery,
captures, and usually with mineral that has been although for a specific system there is usually a
precoated with collectors in a prior flotation. reduction in mineral carrying capacity with an
It is customary to describe the operating conditions of increase in gas rate.
flotation columns in terms of superficial velocities (J) An increase in wash water rate will increase the height
of the fluids, to normalize the information for different of the froth layer, increase the concentrate grade, and
size columns. Typical values are as follows: reduce recovery. The optimum water rate is an
important variable to determine experimentally. Other
Jg = gas velocity ‐0.5 to 3.0 cm/second
variables, such as column height, have a logical effect
Jp = pulp feed velocity ‐ 0.7 to 2.0 cm/ second on flotation; i.e., the higher the column, the greater the
Jw = wash water velocity ‐ 0.1 to 0.8 cm/ second selectivity.
Jb = bias water velocity ‐ 0.07 to 0.3 cm / second In the laboratory, where glass columns are prevalent,
In addition, in scale – up equations it is also this level can be controlled on the feed and the tails,
customary to normalize the gas velocity for different and to vary the wash water as a function of the
height columns by the pressure correction: interface height, which is approximated by a
differential pressure measurement at the bottom of
( Pc)( Jg*)(ln(Pt / Pc)
Jg  the column. As this control method is inherently
Pt  Pc unstable because there is a relation between the froth
Where Jg*= gas velocity is at standard conditions at height and the wash water rate, this is not the ideal
the top of the column, Pc = absolute pressure at the operating (Abdel‐Khalek, 1989, Mckay, et al.1988).
top of the column and Pt= absolute pressure at the In the mineral processing area, all employed flotation
67
devices do not generate microbubbles but coarser with one stage.

bubbles, usually between 600 and 2500 μm. According
v‐ Increased energy efficiency
to most researchers, the lack of “mid‐sized” bubbles in
the cells is the main reason why the capture of the vi‐ Decreased floor space requirement.
very fine particles is inefficient leading to considerable vii‐ Natural adaptability to the computer control
losses, an old problem in mineral processing , because the control is based on flows into and out of
especially for the fine (>13 μm) mineral particles. The the column.
losses are due to the intrinsic properties of these
particles (mainly small mass and low inertia) and Column Flotation Design
main flotation drawbacks are related to the low 1) The Novel Design for flotation Column (Yosry, et
probability of bubble–particle capture phenomena. al.1994)
Many authors have also found high efficiencies of
bubble–particle detachment in fine particles–bubbles Theory:
(coarse) interactions. Many different processes to The theory of Novel designed column flotation which
reduce this problem have been proposed but most of is used in flotation of fine coal is based on creation of a
them have not found practical applications yet. But, flow pattern which has the following characteristics:
this is not the situation in effluents treatment whereby 1‐ Efficient mixing between the mineral particles
most particles are fine (even within the colloidal and air bubbles;
range) and are readily removed by flotation because of 2‐ Fluid flow reversal to enhance the separation
the use of fines bubbles. Accordingly, it may be of pyrite and other ash minerals by gravity.
concluded that for the recovery of fine minerals
3‐ Creation of quiescent zone for pyrite and ash
particles in ore flotation, the cell machine should
minerals separation; and
provide a wide bubbles size distribution, which must
include micro or mid‐sized bubbles (100–600 μm) plus 4‐ Gentle flow, which ensures high recovery of
clean coal in froth.
the coarser bubbles generated in conventional
flotation cells. Column flotation cells generate, with The fulfillment of these principles should ensure
their various commercial spargers, finer bubbles than efficient treatment of fine cleaning and produce high
conventional “rougher” cells machines, improving Btu recovery with satisfactory ash and sulfur removal.
somewhat the recovery of the F–UF mineral particles.
However, determination and report of bubble size
distribution, in this kind of flotation cells are scarce
and more; recoveries of the coarser particles, in
columns, are usually very low and this is another
reason to explain why they are used mostly in cleaner
flotation circuits.
The column flotation has become increasingly popular
over the past few years in mineral industry, primarily
in Canada and USA. The column flotation holds
several distinct advantages over conventional froth
flotation such as the following:
‐ More quiescent separation conditions due to the
lack of tubulence caused by mechanical impellers.
‐ Capability to produce high grade concentrates by
employing:
i‐ Wash water additions to the froth.
ii‐ Increased froth depth.

iii‐ Current flow of bubbles and pulp
FIG.6 LAYOUT OF THE AGGLOMERATE COLUMN FLOTATION
iv‐ often replacing 2‐3 stages of mechanical cleaning SYSTEM
68
As shown in Fig.6, the column flotation system produced a recovery of 75–77 % in a rougher
consists of two main parts namely, the column and the concentrate containing 24% P2O5. In reverse, ASH
bubble generator. system produced a phosphate recovery of 98 % in a
cleaner concentrate containing 31% P2O5. Table 4,
The Air‐ Sparged Hydrocyclone (ASH) flotation
shows the recommended conditions for single–stage
technology is particularly well suited to handle high
rougher and amine flotation with the 2‐ inch ASH
volumes of pulp at a specific capacity 50‐100 times
system. The results, as shown in table 4, are
greater than that offered by other flotation machines.
comparable with those obtained at plant operations in
The specific capacities of various flotation machines
the Florida phosphate industry (Miller, et al. 1999).
are compared in Table 3.
TABLE 3 COMPARISON OF SPECIFIC CAPACITIES OF VARIOUS FLOTATION
MACHINES
Capacity tpd / ft3 ( 20%
Flotation
solids, s.g. 2.5)
Mechanical Flotation Cell 1 ‐5
Flotation Column 1 – 5
Air – Sparged Hydrocyclone 200 ‐ 400

Fig.7 is a schematic drawing of the Air‐Sparged
Hydrocyclone (ASH) which consists of a right vertical
tube having a jacket porous wall, a conventional
cyclone header with a vortex finder, and a froth
pedestal / under flow structure which is centered on
the cyclone axis at the bottom of the porous tube. The
suspension is fed tangentially through the cyclone
header to develop a swirl flow inside the porous tube.
Air passed through the jacket porous tube wall and is
sheared into numerous small bubbles by the high –
velocity swirl flow of the suspension. The fine
hydrophobic mineral particles in the suspension
collide with the bubbles, and after bubbles/particle
attachment, are transported radially into a froth phase,
which forms on the cyclindrical axis. The froth phase FIG.7 A SCHEMATIC DRAWING OF THE AIR – SPARGED
is supported and constrained by the froth pedestal HYDROCYCLONE
and thus moves towards the vortex finder of the TABLE 4 RECOMMENDED CONDITIONS FOR SINGLE ROUGHER AND
cyclone header, being discharged as an overflow froth AMINE FLOTATION WITH 2–INCH ASH SYSTEM
product containing hydrophobic particles. The Specification
hydrophilic particles, generally unwanted gangue Specification of
Items of Rougher
Amine Flotation
particles, are discharged as an underflow stream Flotation
through the annulus created between the porous tube Conditioning pH
Conditioning pulp density 9.2 6.5 – 7.0
wall and the froth pedestal (Miller, et al.1999, Miller et
by Wt% 75 20
al., 1996). Conditioning , minute 5.0 2
Collector dosage *, Ib/t 3.0 1.6 – 2.0
Air–Sparged Hydrocyclone (ASH) flotation Frother *, Ib/t 2.0 ‐
technology has been evaluated for phosphate recovery A* 3.3 2.87
from the Central Florida phosphate deposits in pilot‐ Q* 3.67 4.5
plant experiments (Miller, et al.1999). It was Flotation pulp density by 20 20
Wt% 1.17 1.17
demonstrated that the 2–inch ASH system has a high Vortex finder diameter, inch 3.0 3.0
specific capacity of about 435‐ 550 gpm/ft3 in both Vortex finder depth, inch
rougher flotation and amine flotation system (50–100
times higher than that of a traditional flotation cell). In  Collector dosage : Fatty acid: fuel oil at 7:3 in
case of fatty acid flotation, single–stage ASH flotation rougher flotation and amine in reverse
69
 flotation particle size: finer particles require higher frequency.

 Frother: lion Surf 777. Two jigging frequencies can be superimposed to
assure an effective particle separation while keeping
 A: Ratio of overflow opening area to
particle dispersion (Yang et al., 2003).
underflow opening area.
 Q: Ratio of airflow rate to slurry under flow Applications of Column Flotation
rate.
1) Upgrading Fine Particles of phosphate
2) Packed Column Jig (PCJ)
In 1998, Ityokumbul, continuous experiments were
carried out in a column flotation system to determine
the feasibility of recovering the phosphate values in
phosphatic clays. The contact column is an
improvement over the conventional flotation column
with significantly increased throughput. The heart of
this new separation process is in the turbulent contact
chamber where particle‐bubble contact is affected. As
a result of the turbulent conditions in the contact
chamber, particle collection is complete in about a
second. Thus the flotation column is mainly used to
effect the separation of the bubble‐ particle aggregates.
The contact column has two major advantages: fast
collection that translates to high throughput; and
quitter froth, which is beneficial to higher recovery
from fine feed materials. However, flotation of a bulk
phosphatic clay sample with fatty acid collector
showed no selection of phosphate from gangue
materials (mainly clay minerals and sand).
In 1999, El‐Shall et al., applied column flotation for

upgrading Florida phosphate. Depending on the
FIG. 8 SCHEMATIC REPRESENTATION OF PACKED COLUMN
JIG experimental conditions, it is possible to achieve a
concentrate of high grade ( 61.23% BPL) and
PCJ is a column filled with packing plates which are
recovery ( 84.13 %) from a fine feed sample
corrugated diagonally and set in an alternating
(35x 150mesh) containing about 17.13 % BPL and
configuration. The packing plates create a myriad of
78.45% A.I.
small cells in the column, Fig. 8. A stream of mixed
particles is fed through an inlet located near the top of Application of factorial design to column flotation of
the column. The feed point depends on the feed the fine feed has shed some light on effect of column
characteristics and concentrate grade target. A steady parameters on metallurgical performance. The results
state water flow enters the bottom of the column and a of the central composite design showed that % BPL
pulsating flow is also superimposed to create a jigging recovery is progressively improved with increasing
action that maintains all particles in suspension the collectors dosage from ~ 0.4 to 1.4 IB/t (El‐Shall, at
limiting stagnation problems. Initially, light and fine el., 1999). The BPL recovery is gradually improved
particles move to the top while heavy and coarse with increasing the concentration of froth from 5 ppm
particles move downward based on settling velocities. up to 15 ppm, at which the highest grade is obtained.
A density gradient is formed inside the column, high This is accompanied by a gradual decrease in the
density at the bottom and low density at the top, and estimated bubble diameter. Above such concentration,
each of the product streams is discharged from the both recovery and bubble size are almost constant.
designated outlet. By changing operational conditions, The selectivity of separation process improved by
light‐coarse and heavy‐fine particles are separated using the polyglycol frother at high pH levels. For
either on a size or density basis. A stronger density Instance, the results indicate that F‐ 507, as a non‐
gradient means that particles tend to separate on ionic frother, gave better results at alkaline pH (9.5 to
density criteria. Jigging frequency is set based on 9.8). Response surface contours are generated for %
70
BPL grade and recovery as a function of the studied diphosphonic acid) were evaluated for their
variables, i.e. collector dosage, frother concentration effectiveness for phosphate flotation and the
and pH are within the range of high recovery but performance of three different flotation devices were
slightly more collector(>1.4 Ib/t) needed to get the compared. Finaly, a two‐ stage flotation scheme was
maximum recovery. A concentration of 15ppm of proposed using column flotation of dolomite in the
frother is enough to maximize the recovery. first stage and Denver cell flotation of phosphate in
Meanwhile, a pH of 9.5 closes to optimum for using the second.
such non‐ ionic frother.
In 2013, a flotation column has been designed and
In another study (El‐Shall, et al., 2000), to select the applied in the beneficiation of Al‐Jalamid Saudi
best combination of sparger and frother phosphate phosphate ores of the calcareous type by reverse
flotation, 28 commercially available frothers were scheme (Tariq et al, 2013).The significant parameters
investigated by measuring air holdup under various like superficial gas velocity, slurry feed rate, particle
operational conditions in an air/ water system. An size of processed ore, wash water consumption and
edutor sparger and two‐ phase ejector have strong air collector dosage of flotation process were investigated
dispersion ability, simple operation, less clogging to achieve the best recovery and quality of the
potential and less energy consumption, compared beneficiated ores. The results of this study revealed
with other external spargers. However, the addition of that column flotation technology is a promising tool
such more water to the eductor is required to aspirate for beneficiation of calcareous phosphate ores. A high
atmospheric air into the sparger and to disperse into purity ore of 35% P2O5 can be easily achieved at a high
fine bubbles. For phosphate flotation, the water added recovery value of 95% starting from a rock contains
by eductor meets the requirement for dilution of the 25% P2O5, high calcite content (52.7% CaO) and CaO:
rougher dewatered reagentized feed. In applications P2O5 ratio equals 2.1.
where the feed is not dewatered, the eductor water
2) Upgrading Fine Particles of Hematite
may cause excess water addition to the flotation
system. This problem can be overcome by properly In 2003 ‐ Yang et al. applied Pack Jig Column flotation
selecting the eductor size to minimize the addition technique to beneficiate hematite. Extensive testing
water amount. An economic performance measure has been carried out using a magnetite concentrate
was developed, which includes recovery, grade, and from Mine A and a magnetic taconite crude ore from
the reagent prices. A parametric study was conducted Mine B, which contains 32.8% total Fe, but only 24.8%
on both unsized and sized feed to optimize column is magnetic Fe. In this example, the packed column jig
flotation. can recover both magnetic and non‐magnetic iron
including magnetite and hematite while rejecting light
In phosphate concentrate by using column flotation, it
undesired particles, including those interlocked with
is desirables to achieve an MgO of less than 1.0 % at
iron or other minerals. A crude hematite ore was also
an acceptable P2O5 grade and at an acceptable P2O5
tested to verify PCJ performance on coarser non‐
recovery. In processing dolomitic phosphates, the
magnetic particles. The flow sheet of the process is
flotation separation of dolomite from the phosphate
shown in Fig .9.
minerals is difficult to achieve (El‐Shall, et al.,
2002).The results of the flotation of a primary Yang and co‐ authors, found that , in finely ground
desliming hydrosizer over flow material containing iron ores, the packed column jig yields significantly
high concentrations of dolomite are studied. The higher grades and recoveries than do conventional
phosphate minerals were collophone and francolite. flotation or magnetic separations do; silica levels less
Microscopic examination of the material indicated that than 2% are economically achievable. A two‐stage
all the P2O5 is in the – 150 + 400 mesh (‐106+ 38 μm) packed column jig circuit with reground to reduce
fraction while most of the MgO is in the 270 mesh (‐53 concentrate size can produce higher quality
μm) fraction. The material has not been treated with concentrate at much higher iron recovery than present
flotation reagents. The particular sample studied practices. This is due to its capability to recover non‐
contains 14.6 wt% P2O5 and 3.6 wt% MgO. magnetic iron and its unique design, which prevents
misplacement of particles during separation. Because
In 2002‐ El‐Shall et al., various collectors (two different
no chemicals are used in the process, the column jig is
long chain alkyl sulfonates, a tall oil plus fuel oil, and
environmentally friendly. Due to the simplicity of the
the disodium salt of 1‐hydroxyoctylidene1, 1–
equipment and the circuit, per ton costs are
71
substantially lower than conventional treatments. important in the minerals industry .Aggregation of

fine was developed as a shear flocculation process,
where the hydrophobic particles were aggregated in a
shear field. One possibility for effective agglomeration
can be obtained through the interaction of classical
ionic surfactants (flotation collectors) pre‐adsorbed on
the oxide fine particles with oppositely charged
polymers (flocculants). Sadowski and Polwczk, 2004,
studied the interaction between surfactant and
polymer and the effect of those interactions on
aggregation and flotation of fine particles. Such
interaction may lead to an agglomeration that
combines electrostatic and hydrophobic interactions.
Hydrophobic flocculation arises as a result of
hydrophobic interaction between hydrophobic
particles and oppositely charged or non‐ ionic
flocculant. The separation of hydrophobic flocs can
then be achieved using froth flotation (Song and Lu,

FIG. 9 THE FLOWSHEET OF THE BENEFICIATION OF
2000). The agglomeration flotation process is
HEMATITE BY PACK JIG COLUMN FLOTATION schematically illustrated in Fig. 10. Agglomeration is
formed first, which is then attached to air bubbles and
3) Applications of Prototype Column Flotation
float.
high grade fluorite
Moses and Petersen 2000, studied gold recovery using
In 2007, Aliaga et al were used prototype column
coal/ gold agglomeration (CGA) process, whereby
cell to beneficiate the high grade fluorite samples from
hydrophobic gold particles are recovered from ore
Nossa Senhora do Carmo (NSC)Mining, Criciu´ma
slurries into coal – oil hydrophobic agglomeration.
city, Santa Catarina state, Brazil without wash water
The coal oil agglomeration is separated by settling or
addition. Concentrate flow was obtained by making
flotation technique.
tailing flows smaller than feed flows. Hence, part of
the feed water was carried up within bubble wakes.
Bio-Flotation
No pulp/froth interface was established.
Introduction
A high recovery was obtained in a 2 m collection zone
column. The recovery reached >80% with a grade of~ The large amounts of valuable minerals are discarded
90%. It was found that the recovery depended on the as fines and ultrafines due to inadequate of todayʹs
value of the difference between the feed flow and technology to process them economically. Treatment
tailing flow. In addition, a straight line between the of fine particles presents a difficult problem in the
surface velocity of mineral and the recovery was mineral industry, and its solution is required. These
found. It appears that a maximum capacity of solid is fines can be of substational impact in production, even
~10 g min‐1 cm‐2. at low concentrations and additionally can cause
potential environmental problems, if released to the
Industrial and laboratory‐scale column cells are used
environment (Neidhardt, et al., 1990).
for flotation silica sand for iron and heavy mineral
rejection, limestone for brightness improvement and The biological processes are becoming more attractive
reduction of insoluble, such as kaolin clay and talc for in mineral processing due to their low operating costs
brightness improvement. Column flotation has also and their possible applications to treat difficulty to
been examined in pilot and commercial plants for beneficiate low grade complex ores. Introducing the
flotation of phosphate ores, lithium cleaning and gold biological processes involving microbes for mineral
flotation. processing was first reported by Solojenken et al.
Biological processes are attractive since microbes or
Agglomeration Flotation / Floc- Flotation microbial fat and secreted metabolites can have
Fine particles aggregation and flotation are very specific interactions with minerals. Such interactions
72
of microbes and their agents with minerals can be hydrophobicity.
indirect, with biological products acting as surface‐
Microbe‐mineral interactions yield results that are of
active agents, or direct due to microbial adhesion or
relevance to various applications:
attachment to particles bringing out surface
modification. Both types of interactions can lead to  Adhesion of microorganisms to mineral
alteration of mineral hydrophobicity, and in some substrate resulting in bio‐film formation.
cases cause flocculation or dispersion of mineral  Biocatalysed oxidation, reduction,
suspension. Microbes can also remove toxic metal ions complexation and precipitation reactions.
from ground and surface‐waste‐water by biosorption  Reactions of bacterial cells and metabolic
or bioaccumulation processes. products with different mineral constituents in
Application of Microorganisms in Mineral Processing an ore matrix.
The end result of such biological processes is
Solid – solid interactions are dependent on
formation and conversion of various minerals, surface
biochemical properties and the interfacial properties
modification, selective dissolution of mineral
of the interfaces existing in the system.
constituents and bio‐accumulation of dissolved metal
Microorganisms can be used instead of conventional
ions. Mineral surface hydrophobicity itself can be
chemicals for the following purposes (Smith and
brought about by controlled microbe‐mineral
Miettinen, 2006):
interactions as shown in Fig.11, indicating that water
drops are not spreading on the apatite surface treating
with the microorganism. Metabolic products as well
as the bacterial cell components including the cell wall
and membrane can take part in these microbiological
reactions.

FIG.10 SCHEMATIC REPRESENTATION OF FROTH FLOTATION
OF AGGLOMERATED SPECIES
 To act as leaching agents either directly

attaching to the mineral surface or by
producing acids which aid in leaching.
 To act as surface modifier to enhance the
separation of one mineral from another either
by flotation or flocculation.
 Hydrophobicity.

 Electrostatic Interactions. FIG. 11 HYDROPHOBICITY OF APATITE SURFACE TREATED
 Biosorption of Metal ions. WITH MO WITH BACILLUS POLYMYXA AS ESTABLISHED BY
FROTH FLOTATION
 Biofloccualtion process.
1) Bio‐flotation of Oxide Minerals
 Bioflotation process which includes:
 Bioflotation of sulphide minerals. The difference in surface properties between two
 Desulphurization of Coal. minerals, i.e. hydrophobicity and surface charge were
 Bioflotation of some oxide minerals. utilized for selective attachment of the microorganism,
 Bioflotation of salt type minerals. which in turn led to selective flotation or flocculation.
In both flotation and flocculation, the attachment or In recent years, the microorganism Bacillus polymyxa
adsorption of microorganism to the mineral surface is has been used for bio‐processing of various minerals.
an important process (Attia and Elzeky 1985). The In this case, the microbe was adapted to the particular
attachment is dependent on both the solution mineral, i.e. it was grown in the presence of the
conditions such as pH and ionic strength and the mineral. This approach of adaptation made the
surface properties of the minerals and the organism secrete different bio‐surfactants in the
microorganisms such as zeta‐potential and presence of different minerals thereby making the
73
attachment selective. For example, either paenibacillus 2) Bio‐flotation of Black Shale
polymyxa or its metabolite renders the hematite and TABLE 5 COMPARISON OF FLOTATION PRODUCTS OF BLACK SHALE
corundum surface hydrophilic, Fig. 12 (Shashikala
and Raichur, 2002) . Product Mass Ni Ni ‐ recovery
Wt % % %
Rougher 65.7 0.436 91.8
Flotation
CC1 20.8 0.217 47.4

CC2 25.8 0.229 60.2
CC3 34.5 0.672 74.3

Rougher 72.6 0.39 93.6
Bio‐ flotation I CC1 52.2 0.484 83.4
CC2 29.1 0.648 62.1
CC3 16.8 0.782 43.3

Rougher 64.6 0.451 85.4
Bio‐ flotation II CC1 49.10 0.506 72.7
CC2 42.00 0.539 66.2
CC3 25.10 0.756 55.5

FIG.12 HYDROPHOBICITY / HYDROPHILICITY OF DIFFERENT In 2007, the bio‐beneficiation of multimetal black shale
MINERALS AFTER INTERACTION
ore was studied (Jörg and Reijo), within the
However, similar interactions make quartz surface framework of the EU co‐funded Bioshale project. This
hydrophobic. The above difference in surface project aims to define innovative biotechnological
properties has been utilized to efficiently separate processes for ‘’eco‐efficient’’ exploitation of black
quartz from hematite and alumina. The mechanisms shale ores. The ore sample was from the Talvivaara
responsible for bio‐mineral beneficiation are not fully deposit in Finland. In the black shale ore sample, the
known. Further, it will be helpful to identify various total amount of sulphides was 31.5% of which the Ni‐
physicochemical and biochemical parameters that can minerals pentlandite and altered pentlandite is 0.52%.
influence microbially induced beneficiation processes. Nickel is distributed into pyrrhotite and oxidized
The interactions of P. polymyxa with hematite, pyrrhotite, 32.5%, and pentlandite and altered
corundum and quartz were investigated in order to pentlandite, 66.0%. Other sulphides are chalcopyrite
understand the mechanisms behind its contrasting (Cu), sphalerite (Zn), pyrite (Co) and alabandite (Mn).
behaviour with three minerals (Mesquita et al., 2001). The ore sample contanied 12.3% graphite as a fine
mixture with other minerals. In standard flotation for
In 2001, Mesquita et al, used a non‐pathogenic a feed of 78 μm, a low grade sulphide concentrate
hydrophobic bacterium (RRO 1879) as a flotation with 0.67 % Ni and nickel recovery of 74 % was
reagent in investigation of hematite‐quartz system. obtained from the studied black shale ore, Table 5. The
They found that a strong interaction between cells and mass of concentrate was then 34.5% of the ore feed.
mineral particles, mainly for hematite. The scanning The recoveries of copper and zinc were 91%, of cobalt
electron photomicrograph was showed the presence 89% and of manganese 53%. The content of carbon in
of RRO 1879 cells adhered on mineral surfaces. the concentrate was 11.3% as graphite represents a
naturally floating harmful mineral in the ore. The
For a constant ionic strength (0.1 m M NaCl), the
bioflotation tests showed that collector chemicals, i.e
change on the surface properties showed a high
xanthates, had to be supplied to achieve reasonable
influence of pH on the adhesion process, and both
flotation results. Out of the three tested bacterial
physical and chemical mechanisms would be involved strains, Staphylococcus carnosus, Bacillus firmus and
in particles and cells interaction. Bacillus subtilis, the minor hydrophobic strain S.
The selectivity for hematite flotation against quartz carnosus yielded the best test results.
was observed in the tests, by using a synthetic
Contribution of CMRDI in Flotation of Fine Particles
minerals mix, showing the potentiality for using RRO
1879 cells as a collector, in a neutral pH, in flotation The author applied (Abd El‐Rahiem,1997) the carrier
systems where iron grade is low, or in materials where flotation technique, as an alternative to conventional
hematite is a contaminant. flotation, can be successively applied for separation on
74
anatase impurities from the Egyptian kaolin affected. As the size of carrier increases above a
preconcentrate, of El‐Tih locality at Sinai, see Table 6. certain value, the hydrophilic exceeds the ability of
In this technique the amount and grain size of the bubbles to levitate such a large and relatively
carrier play a very important role in determining the hydrophilic aggregate, leading to a significant
performance of the flotation process. The best results decrease in flotation efficiency.
are obtained while adding 133.33 kg/ t of limestone, as
It is well known that during the beneficiation of
a carrier. The presence of such carrier particles
phosphate ore, 25 – 35 % by weight of the ore is
increases the aggregation rate of carrier–anatase
discarded as slimes (‐45μm). For example, in Florida
aggregates thereby facilitating their rate of collision
phosphate industry, about 1/3 of the feed is lost as
with air bubbles and consequently improves the
efficiency of the flotation process. Moreover, the long phosphatic clay slimes. In Sebaiya West , Egypt, such
conditioning time which requires froth flotation can slimes represent about 25‐30 % of the feed. For this
be significantly reduced from 35 to 20 min. in carrier reason, the author tried to recover such fine phosphate
flotation technique. Such reduction in conditioning column flotation.
time will decrease the power consumption needed for During the beneficiation of Sebaiya West phosphate,
the process. Egypt, application of column flotation for recovery of
Application of carrier flotation technique for fine particles (‐ 45 μ m), Table 7, indicated that the
upgrading of Egyptian kaolin preconcentrate , using optimum conditions are : superficial gas velocity 0.84
83.33 kg/t of limestone with grain size of ‐25 + 10 μm , cm/sec., frother concentration 0.1 kg/ton, column
and the aforementioned optimum conditions of froth height 230.5 cm and superficial wash water velocity
flotation, gave a concentrate of 0.61 % TiO2 only with 2.2 cm/sec. At such condition ,a concentrate assaying
degree of whiteness (~ 90), from a feed assaying 1.52 % about 25.30 % P2O5 and 14.64 % I.R. from the original
TiO2 with degree of whiteness 56. feed, which contains 18.26 % P2O5and 24.68 % I.R.
TABLE 6 EGYPTIAN KAOLIN CONCENTRATION PRODUCE BY DIFFERENT
with on operational P2O5 recovery of about 76.50 %,
FLOTATION TECHNIQUES was obtained. Such grade and recovery are not
obtained by the conventional froth flotation process
Flotation Process Whiteness
for upgrading such fines even after a stage of cleaning.
Conventional 78 The grade of the concentrates obtained by column
Carrier 90 flotation can be improved by altering the amount of
Column 91.5 wash water used, which help in minimizing the feed
water recovery by washing the entrained , non‐floated
Feed 56
particles from the floatable bubble‐ particle

aggregates(Abd El‐Rahiem,1997) .
The author (Abd El‐Rahiem, 2003) used carrier
flotation technique for decreasing sulfur content and Also, applying column flotation technique on Sebaiya
ash from fine particles (‐ 25 μm) of El‐Maghara coal West phosphate sample (100% ‐ 75 μ m), Egypt, table
from Egypt. A highly floatable coarse coal is capable 7, gave a concentrate assaying 30.4 % P2O5 and only
of carrying fine and difficult‐to‐float coal through 8.64% IR. With total recovery of about 70.24%. Such
some kind of heterocoagulation process. The best size grade and recovery have never been obtained before,
for the present system is ‐0.3+ 0.1mm. The higher the through the conventional froth flotation technique, at
amount of fine carried coal for the same size of carrier; the flotation plant at Sebaiya West, Egypt, even after
the lower is the flotation performance. The ratio of two cleaning stages. Such superior results obtained by
0.02 for carrier by weight is found to be suitable to column flotation technique may suggest its
achieve good flotation performance. The mechanism application at Sebaiya West, as a new technique, may
of the carrier flotation process is ascribed to the have many advantages: first, reducing the operating
electrostatic forces between the positively charged costs of phosphate production by saving the cleaning
carrier particles (+20 mV) and negatively charged stages which are actually performed at Sebaiya West,
particles (‐20 mV) of fine coal. The attraction is second maximizing the values of Egyptian phosphate
governed by the hydrophobic/hydrophilic balance at by producing high grade concentrates suitable for
the carrier carried surface. As the carrier size exportation and for manufacturing of high quality
approaches that of the carried size, it is adversely complex phosphatic fertilizers.
75
TABLE 7 RESULTS OF COLUMN FLOTATION ON SEBAIYA WEST PHOSPHATE Aero 825 with consumption of 300 g/t. Also, Na2SiO3
SAMPLE
was used as carbonate depressant with the
Grinding Size, P2O5 % I.R. % P2O5 % consumption of 100 g/t. The frother was employed
mm recovery
Aerofroth 71 of Cyanamide with 100g/t of
‐ 0.045 25.30 14.64 76.50
‐ 0.075 30.40 8.64 70.24 consumption. Finally, the superficial flow rate of wash
Feed 18.26 24.68 ‐‐‐‐‐‐ water was 1.5 cm/sec. At such conditions, a
concentrate assaying 1.48 % CaO and 5.40 % L.O.I.
The author applied (Abd El‐Rahiem, 2004) column with a recovery 95 % was obtained from a feed
flotation technique to separate graphite from Um containing 6.32 % CaO and 11.53 % L.O.I., Table 9.
Qureia ore, taken from Eastern desert of Egypt. The
flotation of fine particles (‐45μm) using conventional
cell, a rougher concentrate about 34 % C with recovery
38 % was obtained from a feed assaying 15.58 %
carbon content, Table 8. However, applying
flotation at its optimum conditions, a rougher
concentrate at 36 % C with recovery 93 % was
obtained. In cleaning of rougher concentrate 4 stages
are needed by conventional cell to get a concentrate of
about 71 % C with recovery 87 %. In cleaning of
rougher concentrate by column flotation, needed 2
stages to get better grade about 79 % C and about 98
%. Thus the column flotation is better than
conventional flotation in fine particles of graphite.
TABLE 8 COMPARISON OF RESULTS OF CONVENTIONAL CELL AND
COLUMN
- 45
+ 45 μm
μm
Details
Colu
Cell Cell Column
mn
Weight %
41.07 45.30 44.70 47.90
Carbon content %
70.59 78.55 45.17 46.14
Carbon recovery %
86.60 98.30 89.17 96.05
No. stage of
4 2 4 2
cleaning FIG .13 FLOWSHEET OF THE BENEFICIATION OF TALC BY
33.99 % COLUMN FLOTATION TECHNIQUE
Feed 22.86 % Carbon
Carbon
These results indicate clearly the supremely of the

column flotation in floating such fine particles of talc
The flotation of coarse particles + 45μm, almost similar
where the selectivity in separation carbonate (as CaO
results were obtained either by cleaning in 4 stages by
and L.O.I.) is significantly need in the concentrate.
conventional cell or 2 stages by column flotation. Thus
the performance of column is better compared to cell TABLE 9 COMPLETE CHEMICAL ANALYSIS OF THE ORIGINAL AND FINAL
CONCENTRATE OF TALC
by reducing the number of stages required for
flotation of coarse particles of graphite, and also Constituent % Original concentrate
improving the recovery. MgO 28.41 30.05
SiO2 49.71 57.04
Also, The author applied (Abd El‐Rahiem, 2005), used CaO 6.32 1.48
column flotation technique to beneficiate Fe2O3 1.15 0.76
preconcentrate talc sample of Shalatin locality in the L.O.I. 11.53 5.40
Eastern Desert at the following conditions feed (‐ 75 Na2O 2.11 0.13
μm), the flow sheet in Fig. 13., at Column height 225 Al2O3 0.13 3.63
cm, with 30 % pulp density at pH 6.5, while superficial TiO2 0.02 0.02
air flow rate was 4 cm/sec. The collector used was MnO 0.04 0.04
76
In 2008, Abdel‐Khalek and co‐ author used bio‐ collector concentration. The results of these tests were

flotation technique to beneficiate a low grade sample shown in Fig. 14.
of phosphate ore (Abu‐Tartur area, New Valley,
Egypt). Microorganisms were used mainly as surface
modifiers for either apatite or dolomite surface,
leading to better selectivity for adsorption of collector
on the mineral surface. In most of phosphate flotation
plants, fatty acids (e.g. oleic acid or oleate) are used as
collector for direct flotation of phosphate minerals
from their associated gangue (mainly silica). Since
oleic acid was a conventional collector, the bio‐
flotation experiments aim at comparing its efficiency
to a second collector known as amphoteric. The latter
shows better selectivity towards carbonate flotation FIG. 14 EFFECT OF COLLECTOR DOSAGE ON MGO REMOVAL
(Yassin, 2004). Preliminary flotation experiments were AT DIFFERENT PHS AND BACTERIA CONCENTRATIONS
conducted, as control tests, using both collectors The best grade (0.78%MgO and 30.2%P2O5) with a
without addition of microorganisms, the results of high recovery (92.6%) was obtained at pH~5.5, 2.0 kg t‐
which are shown in Table 10. 1 sodium oleate and a concentration of bacterium # 1
TABLE 10: CONTROL TESTS FOR FLOTATION OF PHOSPHATE SAMPLE WITH of 1.0 x108 cells. In the absence of bacteria, such grade
BOTH COLLECTORS and recovery could not be obtained. Also, it was
P2O5 found that strong interaction between sodium oleate
Collector type P2O5% MgO % recovery and the bacteria enhances the selectivity of the
%
flotation process. Both microorganisms (coded #1 &
Amphoteric
(4.0 kg/t)
29.15 1.12 75.43 #2) have minor electro‐negativity especially in the
Oleate (0.25 acidic medium. Their zeta potential slightly increased
30.19 0.84 55.52
kg/t) (by not more than 12 mv) with raising the pH from the
Oleate (> 0.25 very acidic medium (pH 2) to the strongly alkaline
Bulk flotation with 100 wt % floated
kg/t)
medium of pH 12. These results illustrate the
Flotation Feed 27.07 2.24 ‐‐‐‐‐‐‐‐‐‐

hydrophobicity of these microorganisms.
Two types of bacteria were used in the bio‐flotation In 2004, enzyme, obtained from Aspergillus’s Niger F–
process. These bacteria were isolated from the surface 909 cultures, was used as a surface modifying agent
of Abu‐Tartur phosphate ore at the Microbiology during phosphate fatty acid flotation to beneficiate a
Department, University of Florida, USA. Two of them low grade sample of phosphate ore (Abu‐Tartur area,
were selected for the bio‐flotation experiments. The New Valley, Egypt). The results revealed more
bacteria were grown in a liquid medium containing efficient separation of carbonate from phosphate rock.
30% mycological agar, 10.0 g L‐1 sucrose,1.0 g L‐1 The Concentrate at 0.70 % MgO with recovery 86.41%
ammonium nitrate and 700 mL double distilled water. was obtained from a feed containing 2.88 % MgO.
The bacteria were incubated at 25°C for two weeks
(Yassin, 2004). Conclusions
Control tests, without addition of bacteria, were  The problems associated with the presence of
conducted using 0.25 kg t‐1 sodium oleate at pH fine particles are most pronounced in flotation.
5.5.The results showed that starting from feed There is a general agreement that flotation
containing 27.07%P2O5 and 2.24%MgO, a concentrate decreases with a decrease in particle size in the
contains 30.2%P2O5 and 0.85%MgO can be obtained fine particle range. The flotation of fine
but at a low recovery (55.5%). Using a higher sodium particles need the long conditioning time and
oleate concentration (>0.5 kg t‐1) resulted in bulk need long flotation time.
flotation (100 wt‐% floated) of the flotation feed with  The carrier flotation technique has the
no selectivity. advantage of reducing the long conditioning
Other flotation tests were conducted to clarify the time needed for the pulp with the reagents in
effect of pH and bacteria concentration in terms of the conventional technique.
77
 The main draw backs of carrier flotation Processing and Environmental Protection, Vol.4, No.2,
process in mineral beneficiation operations, are
1303‐0868, pp. 91‐94., 2004.
high reagent consumption and the necessity
Abdel‐Khalek, N.A., Ph.D. Thesis, Mining Faculty,
for subsequent separations of valuables from
the carrier particles (when the valuable University of Mining and Metallurgy, Cracow, Poland,
minerals are being recovered in the froth). 1989.
 There is a great potential to recover fine Attia, Y. A. and Elzeky, M. A., Biosurface Modification in
particles from their gangue using the recent the Separation of Pyrite from Coal by Froth Flotation,
technology such as column flotation or ASH Processing and Utilization of High Sulfur Coals,
after its modification to be suitable for flotation
Elsevier, Amsterdam, 673‐682, 1985.
of very fine particles.
Chander, S., Recent Developments in Floatability of Very
 The biological processes are becoming more
Fine Particles–Review, Trans. Indian Institute of Metals.
attractive in mineral processing due to their
lower operating costs and their possible Vol. 31, p.21, 1978.
applicatios to treat difficult to beneficiate low Dobby, G.S. and Finch, J.A., Mixing Characteristics of
grade complex ores. Industrial Flotation Columns. Chemical Engineering
Science, Vol 40, No.7, pp. 1061‐1068, 1985.
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Recent Trends Flot Fine Particles

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Journal of Mining World Express Volume 3, 2014 www.mwe‐journal.

Problems of Fine Particles flotation.

Fine Particles Carrier Flotation of Fine Particles

Entrainment High charge Non specific adsorption 1. presence of coarse particles

The possibility to improve the floatability of fine

It is not always necessary to externally add particles as The principle operating features of column flotation

devices do not generate microbubbles but coarser with one stage.

 flotation particle size: finer particles require higher frequency.

substantially lower than conventional treatments. important in the minerals industry .Aggregation of

 To act as leaching agents either directly

In 2008, Abdel‐Khalek and co‐ author used bio‐ collector concentration. The results of these tests were

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